Connector systems for building materials

ABSTRACT

A connector ( 15 ) for connecting modules together comprises plastic connector member ( 16 ), an expander rod ( 17 ) and a threaded expander rod displacer ( 18 ). The connector member ( 16 ) has spaced dovetail style enlargements ( 19 ) on one side and a full length dovetail enlargement ( 20 ) on the other side. The connector member ( 16 ) is designed to slide in the confronting slots with the wasted sections ( 21 ) of the expander ( 17 ) located inside each of the sections ( 19 ). Once in position the threaded expander rod displacer ( 18 ) is used to axially displace the expander ( 17 ) to force the enlarged sections of the expander ( 17 ) into the sections ( 19 ) thus engaging the slot and at the same time biasing the modules together.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is an U.S. national phase application under 35 U.S.C.371 based upon co-pending International Application No.PCT/AU2003/001332 filed on Oct. 9, 2003. Additionally, this U.S.national phase application claims the benefit of priority of co-pendingInternational Application No. PCT/AU2003/001332 filed on Oct. 9, 2003,Australian Application No. 2002951928 filed on Oct. 9, 2002, andAustralian Application No. 2002953020 filed on Dec. 2, 2002. The entiredisclosures of the prior applications are incorporated herein byreference. The international application was published on Apr. 22, 2004under Publication No. WO 2004/033925 A1.

TECHNICAL FIELD OF THE INVENTION

THIS INVENTION relates to a connector and associated constructionmethods and systems and in particular but not limited to constructiontechniques and methods concerning exterior modular building materials,typically windows.

BACKGROUND TO THE INVENTION

Many arrangements are used to connect building panels in edge to edgerelation. Typical arrangements are tongue and groove arrangements. Somearrangements involve cooperating edge configurations where bridgingfitting is used to secure the panels together.

Australian Patent No 540685 uses a panel where the edge is and I-shapedtongue which effectively has side slots and is fitted freely into a slotwith a cross shape in profile on the other panel, the cross shaped sloteffectively has opposed side slots align with side in the slots in thetongue resulting in longitudinal spaces on either side of the tongue andbridging the tongue and the slot. The panels are locked together by pinsor rods located in the spaces thus blocking removal of the tongue.

DE2343047 connects panels using alternating hook like lobes separated byrecesses. The lobes and recesses are the same width and are offset oneach panel.

GB2291687 describes panel edges having lugs and recesses so the lugs fitinto the recesses of the other panel, each lug has a through hole andthey all line up so a rod through the lugs locks the panels together.

OUTLINE OF THE INVENTION

In one aspect there is provided a connector system for connecting twomembers together, the connector system comprising a connector member anda connector member expander, the connector member in profile havingenlarged ends and a narrower intermediate section between the ends, oneend having a slot to receive the connector member expander to expand theslot so the enlarged end is biassed to retentively engage a body locatedadjacent the intermediate section.

Preferably, the connector member is generally I-shaped in profile havinga central web connecting opposed pairs of bilaterally projecting arms,at least one set of arms having the expandible slot so that upon axialmovement of the expander in the slot, the set of arms are biassed towardthe other set of arms.

The connector member is typically shaped or configured to match the bodythat is located adjacent the intermediate section. The connector membermay have two or more ends, all the ends may have slots and correspondingexpanders.

In one embodiment the connector member is a short plug and the expanderis a grub screw. In another embodiment the connector member is a longstrip and the connector member is a rod driven onto the slot.

Preferably, the connector member is an elongate strip, the enlarged endsextending along opposite edges of the strip, the enlarged ends on atleast one edge being separated by gaps, the expander comprising a rodhaving spaced enlargements each functioning as connector expanders, theenlargements on the rod being separated by narrower regions thatinitially locate in the expandable slots and upon axial movement of therod the enlargements move into the slots to expand the slots.

The T-shaped ends preferably include peripheral longitudinal beadingthat contacts the body. The connector member preferably has armsprojecting from the narrow intermediate section, there being a juncturebetween the arms and the intermediate section, there being a small slotat the juncture of the arms being adapted to close or partially close asthe arms are biassed. Each arm preferably has a bead extending along anedge of the arm, the bead providing a focal line for the bias.

The expander may be a pin, screw, rod or other means. The expander maycomprise a single expander or multiple expanders. The expander may haveexpander section separated by narrow non-expander sections and belocated wholly within the connector member until driven into expandingposition by an expander displacer.

The connector members may be short or long.

The expander may be one way or reversible so that the connector membermay release the body held when the expander is reversed. As aconsequence application of the expander may vary. Where the expander is,for example, a grub screw it may be applied and reversed using aconventional tool. The expander may be driven by a hammer from one endand reversed by operation from its opposite end by driving a rod orscrew into the opposite end of the slot.

Preferably, the expander has tapered enlargements, the taperedenlargement preferably being tapered at opposite ends, so that theexpander is reversible. The enlargement may be fluted to reducefriction.

In a preferred application of the invention there is provided incombination a modular window system comprising window modules and awindow module connector system, each window module having slotted outerframe members, the connector system comprising an elongate connectormember and a connector member expander, the connector member beingadapted to retentively engage the slots in the slotted members uponapplication of the expander to the connector member.

In another invention there is provided an improved window frame assemblyhaving a sash, a sill and a seal disposed between the sash and sill, theseal having a section adjacent a lower edge of the window assembly, thesill and sash having complimentary lower marginal sections outboard ofsaid seal and extending along at least the lower edge of the windowassembly, the lower marginal sections defining there between an inclinedwater flow passage means, the water flow passage means being downwardlyinclined from a position adjacent said seal to the edge of the windowassembly. This window frame assembly may be utilized in the modularwindow system described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the present inventions may be more readily understood andbe put into practical effect reference will now be made to theaccompanying drawings which illustrate preferred embodiments, and oneapplication of the connector system as applied to a modular windowsystem, it will be appreciated that the connector system has generalapplication and wherein:

FIGS. 1A, 1B and 1C are schematic drawings illustrating a connectorsystem as applied to modular windows and employing in profile a dovetail shaped connector member;

FIG. 2 and FIG. 3 are drawings of part sections through lower marginalsections of typical window assemblies;

FIG. 4 is a schematic drawing illustrating the arrangement of modulestypical in the applicant's modular window system;

FIGS. 5 and 6 illustrate a further embodiment employing in profile anI-shaped connector member;

FIGS. 7 to 9 illustrate different expanders;

FIGS. 10 to 12 illustrate operation of the connector in a panel edge toedge operation;

FIGS. 13A and 13B illustrate operation of a short connector in a side byside panel arrangement;

FIG. 14 is a profile of a four ended connector;

FIG. 15 is a profile of a three ended connector;

FIG. 16 is a profile of a hinge connector;

FIGS. 17 and 18 are drawings illustrating typical tools for applying theexpander using a hammer action;

FIG. 19 is a drawing illustrating a gear assembly for applying theexpander in situations where axial tool access is not available;

FIGS. 20 and 21 are drawings illustrating a setup for pulling anexpander into position rather than pushing;

FIGS. 22 to 25 are drawings illustrating various connector memberprofiles; and

FIG. 26 is a section showing external application of the connector.

METHOD OF PERFORMANCE

The following description deals with application of the connector systemto external windows where the ability of the connector system to drawthe two parts being connected together is considered beneficial. It willbe apparent however that the connector has general application and thefollowing description is non-limiting.

Referring to the drawings and initially to FIGS. 1A to 1C there isillustrated a modular window system employing window modules 10 and 11which may be connected together to form a modular assembly 12. Eachmodule has spaced dovetail slots 13 and 14 which are positioned inconfronting relation as shown in the inset of FIG. 1B and the modulesare retained together by connectors 15 engaged in the slots. A typicalconnector is illustrated in exploded form at 15 in FIG. 1C.

The connector 15 comprises a plastics connector member 16, an expanderrod 17 and a threaded expander rod displacer 18. The connector member 16has spaced dovetail style enlargements 19 on one side and a full lengthdovetail enlargement 20 on the other side. The connector member isdesigned to slide in the confronting slots 13 and 14 with the wastedsections 21 of the expander 17 located inside each of the sections 19.Once in position the threaded expander rod displacer 18 is used toaxially displace the expander 17 to force the enlarged sections 22 ofthe expander 17 into the sections 19. This has the effect of not onlyengaging the slot but at the same time of biassing the modules together.

It will be appreciated that the connector parts may be of any shape andconfiguration that is able to achieve the mechanically equivalentfunction described.

FIGS. 2 and 3 illustrate two different modules being a lower section ofa double hung window at 24 and typical awning and casement windowsection at 25. Common to these is the sloping section 26 of the sill 27outboard of a seal 28. In each case a sash 29 is complimentary with thesill 27.

FIG. 4 illustrates typical modules and modular assemblies that may bemade using the teachings of the present invention.

FIGS. 5 and 6 illustrate a further embodiment adapted to a differentshaped slotted profile, the connector member 30 in this case is I-shapedand operates with an expander as described. The slotted members that areconnected together have confronting T-shaped slots corresponding to halfthe profile of the connector member. FIG. 6 illustrates the way arms 31and 32 are biassed inwardly (unexpanded position in phantom) under theinfluence of the expander.

FIGS. 7 to 9 show expanders 33, 17 and 34 respectively. The expanders 33and 34 have a double taper at 35 and 36 to enable reversal should onewant to disconnect. The expander 17 is less easy to reverse and theslots 37 in FIG. 4 may be molded with a small catch to engage shoulder38 in order to prevent or inhibit reversal. The expander 34 has flutedand double tapered enlargements. This limits friction and isparticularly suited to longer embodiments.

FIGS. 10 to 11 show the connector assembled in slotted panels 38 and 39,the panels 38 and 39 have T-shaped slots routed in the edges so that theresulting combination corresponds in profile to a marginally larger thanthe connector 30 but still a workable fit. The expander is in place inFIG. 10 in its release position. FIGS. 11 and 12 show the application ofthe threaded expander displacer 18. The connector member has arms31,32,40 and 44. Each arm has a bead 45, arms 31 and 32 at the junctureof the arms 31 and 32 with the web 46 has small slots 47. The slots arein the corner, the effect of the small slots 47 is to limit the materialresistance to the arms assuming the inward retentive action shown inFIG. 12 while the beads provide focal lines for the applied bias force.

FIG. 13A illustrates a short connector member 48 having the same profileas connector 30 but does not utilize the long expander, rather it uses agrub screw as the expander. Correspondingly short slots 50 and 51 inpanels 52 and 53 may be employed as illustrated in FIG. 13B.

FIG. 14 is a profile of a four ended connector 54, it has T-shaped ends55,56,57 and 58 which are each effectively the same configuration as thedeformable ends of the connector 30. It will be clear that the edges offour panels may be connected in a cross shape with adjacent panels at 90degrees. In FIG. 15 connector 59 has three ends 60,61 and 62 and butwould have the panels at 120 degrees.

The versatility of the invention is dramatically illustrated by FIGS. 16and 19. FIG. 16 is a hinge connector 63. In this case a hinge with a pinat 64 is formed in the usual way but is retained in the slots shown inphantom by the present invention. Two set of non-flexing arms 65 areadded to improve the gripping action although only the flexing arms 66are required. The size of the panels supported may dictate the number ofarms required.

FIGS. 17 and 18 illustrate driving methods to apply the expander orexpander displacer.

FIG. 19 illustrates a gear assembly 67 of the rack and pinion type whichmay be used in situation where axial access to drive the expander is notavailable as might be the case between floors. In this case theexpanders have threaded ends 68 and are permanently coupled to the racks69 so they may be pulled or pushed and the panels may be released later.FIGS. 20 and 21 illustrate a pulling action to apply the expandersimilar to a rivet tool. FIGS. 22-25 illustrate variations in profilefor different applications. FIG. 26 illustrates external use of theinvention.

Whilst the above has been given by way of illustrative example manyvariations and modifications will be apparent to those skilled in theart without departing from the broad ambit and scope of the invention asherein set forth in the appended claims.

1. A connector system for connecting members together, the connectorsystem comprising a connector member and a connector member expander,the connector member in profile having enlarged ends and a narrowerintermediate section between the ends, one end having a slot to receivethe connector member expander to expand the slot so the enlarged end isbiassed to retentively engage a body located adjacent the intermediatesection, wherein the connector member expander has an expander sectionserarated by narrow non-expander sections and in use be located whollywithin the connector member until driven into expanding position by anexpander displacer.
 2. The connector system according to claim 1 whereinthe connector member is generally I-shaped in profile having a centralweb connecting opposed pairs of bilaterally projecting arms, at leastone set of arms having the expandible slot so that upon axial movementof the expander in the slot, the set of arms are biassed toward theother set of arms.
 3. The connector system according to claim 1 whereinthe connector member is shaped to match the body that is locatedadjacent the intermediate section.
 4. The connector system according toclaim 1 wherein the connector member is a-short plug and the expander isa grub screw.
 5. The connector system according to claim 1 wherein theconnector member is an elongated strip and the connector member expanderis a rod driven onto the slot.
 6. The connector system according toclaim 1 wherein the connector member is an elongate strip, the enlargedends extending along opposite edges of the strip, the enlarged ends onat least one edge being separated by gaps, the expander comprising a rodhaving spaced enlargements each functioning as connector expanders, theenlargements on the rod being separated by narrower regions thatinitially locate in the expandable slots and upon axial movement of therod the enlargements move into the slots to expand the slots.
 7. Theconnector system according to claim 1 wherein the connector member has aT shaped end with the slot medially located, the T-shaped end includeperipheral longitudinal beading that contacts the body.
 8. The connectorsystem according to claim 1 wherein the connector member has armsprojecting from the narrow intermediate section, there being a juncturebetween the arms and the intermediate section, there being a small slotat the juncture of the arms being adapted to close or partially close asthe arms are biassed.
 9. The connector system according to claim 1wherein the connector member has arms projecting from the narrowintermediate section, each arm having a bead extending along an edge ofthe arm, the bead providing a focal line for the bias.
 10. The connectorsystem according to claim 1 wherein the expander is reversible torelease the connector.
 11. The connector system according to claim 1wherein the expander has tapered enlargements, the tapered enlargementbeing tapered at opposite ends, so that the expander is reversible-heand the enlargement may be fluted to reduce friction.
 12. The connectorsystem according to claim 1 wherein the expander has taperedenlargements, the tapered fluted enlargement being tapered at oppositeends, so that the expander is reversible.
 13. A modular window systemcomprising window modules and a window module connector system, eachwindow module having slotted outer frame members, the connector systemcomprising an elongate connector member and a connector member expander,the connector member being adapted to retentively engage the slots inthe slotted members upon application of the expander to the connectormember, wherein the connector member expander has an expander sectionserarated by narrow non- expander sections and in use be located whollywithin the connector member until driven into expanding position by anexpander displacer.
 14. The modular window system according to claim 13wherein the elongate connector member is generally I-shared in profilehaving a central web connecting opposed pairs of bilaterally projectingarms, at least one set of arms having the slots so that upon axialmovement of the expander in the slots, the set of arms are biassedtoward the other set of arms.
 15. An improved window frame assemblycomprising a sash, a sill and a seal disposed between the sash and sill,the seal having a section adjacent a lower edge of the window assembly,the sill and sash having complimentary lower marginal sections outboardof said seal and extending along at least the lower edge of the windowassembly, the lower marginal sections defining there between an inclinedwater flow passage means, the water flow passage means being downwardlyinclined from a position adjacent said seal to the edge of the windowassembly, and further comprising a connector member and a connectormember expander, the connector member in profile having enlarged endsand a narrower intermediate section between the ends, one end having aslot to receive the connector member expander to expand the slot so theenlarged end is biassed to retentively engage a body located adjacentthe intermediate section, wherein the connector member expander has anexpander section separated by narrow non-expander sections and in use belocated wholly within the connector member until driven into expandingposition by an expander displacer.